Comparative assessment of ultrasound application modes in coal flotation: A Box–Behnken-based optimization study

İngilizce (OpenAlex)

In this study, the effect of ultrasound treatment on coal flotation was investigated using two methods: ultrasonic pretreatment flotation (UPF) and simultaneous treatment flotation (USF). A Box – Behnken experimental design was used to evaluate the individual and interactive effects of ultrasonic power, treatment time, collector concentration, and frother concentration on ash content (AC) and combustible recovery (CR). The results showed that ultrasonic power and treatment time increased AC but reduced CR for both methods. With UPF, AC was 9.89–23.96% and CR was 45.21–80.26%, while with USF, AC was 8.73–22.63% and CR was 67.21–84.97%. USF showed higher recovery and required less reagent. Contact angle and zeta potential measurements supported the flotation results. Regression analysis yielded high R2 values, validating the model’s reliability. The optimum conditions were 60 W ultrasonic power, 3 minutes of treatment, and 0.5 kg/ton frother. The ideal collector dosage was 1 kg/ton for UPF and 0.4 kg/ton for USF. These findings emphasize that the mode of ultrasound application and process parameter selection are both key to enhancing flotation performance.